A coalition of innovative companies has pioneered the creation of a digital twin designed to enhance microbial protein production. This initiative, led by Novasign based in Vienna, aims to significantly reduce the costs associated with producing microbial proteins by optimizing experimental design.
The digital twin technology promises to decrease the number of experiments needed to analyze process behavior by up to 70% when compared to traditional Design of Experiments (DoE) methods. Mark Duerkop, PhD, CEO of Novasign, emphasizes the challenges faced by the industry, stating, “The biggest problem in the industry right now is it’s not very efficient.” He advocates for the need for improved methodologies that enable more effective learning from experiments, better experimental designs, and adaptive responses to process deviations.
The Development Journey
Three years ago, Novasign embarked on the ambitious project of developing a comprehensive digital twin that encompasses the entire microbial protein production process as part of the ECOnti consortium. The goal of this digital twin is to enhance both process development and overall manufacturing efficiency.
Duerkop explains that the digital twin offers systematic recommendations for subsequent experiments, guided by insights derived from modeling. This capability not only aids in process development but also plays a critical role during the manufacturing phase by identifying deviations from the planned process trajectory and facilitating necessary corrective measures.
Enhancing Manufacturing Resilience
The potential applications of the digital twin are broad. For instance, in scenarios where the production process faces disturbances like pH shifts or feed pump failures, the digital twin can assist manufacturers in recovering from these setbacks, potentially minimizing product losses.
However, Duerkop notes that the implementation of self-optimizing or autonomous manufacturing processes requires extensive validation by regulatory bodies, such as the U.S. Food and Drug Administration (FDA). This validation is a critical step before fully realizing the benefits of such advanced technologies.
Real-World Application and Impact
At the recent Bioprocessing Summit Europe, Duerkop showcased the capabilities of Novasign Studio software, demonstrating its effectiveness in controlling processes over a continuous 30-day period. He illustrated how the software utilizes data from small-scale experiments to guide scale-up processes efficiently. In sectors such as biosimilar development and viral vector manufacturing, the software can reduce experimental efforts by as much as 64%.
The Future of Bioprocessing
This innovative approach signifies a substantial shift in how microbial proteins are produced, potentially leading to more sustainable practices within the industry. As digital twins become increasingly integrated into bioprocessing, they hold the promise of not only reducing costs but also enhancing the efficiency and reliability of protein production.
In conclusion, the digital twin process represents a transformative advancement in microbial protein production. By significantly optimizing experimental design and manufacturing processes, this technology could pave the way for more efficient and cost-effective solutions in biotechnology.
- Key Takeaways:
- Digital twins can reduce experimental requirements by up to 70%.
- They facilitate real-time corrections during manufacturing processes.
- Regulatory validation is essential for fully autonomous systems.
- Small-scale experimental data can dramatically enhance scaling efforts.
- This innovation is poised to revolutionize the microbial protein industry.
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